Polyester, polycarbonate and polyamide blends and articles having enhanced balance of glow wire ignition temperature, comparative tracking index, and flame retardant properties

ABSTRACT

The invention relates to a molding composition containing: (a) a polycarbonate component; (b) a polyester component; (c) a polyamide component; (c) a halogenated flame retarding component; and (d) a carboxy reactive component. The composition exhibits excellent properties that are highly useful in applications such as electronic components. The composition may also contain other components, such as impact modifiers. The invention also relates to articles made from the composition as well as methods of making and using the composition.

This application claims priority to U.S. Provisional Application No.60/803,925, which was filed Jun. 5, 2006, incorporated herein in itsentirety.

BACKGROUND OF THE INVENTION

Manufacturers of electrical components such as relay housing controls,timer housing structures, connectors, controls and switches have anongoing need for materials that exhibit properties that are suitable forthe components' intended operating conditions. Electrical componentsthat exhibit poor performance properties, for instance, can causeelectrical fires, device malfunctions, resulting in property andphysical injuries. It is imperative that electrical componentmanufacturers develop products that avoid such malfunctions.

Polycarbonate is a useful engineering plastic for parts requiringclarity, high toughness, and, in some cases, good heat resistance.Polycarbonates, however, also have some important deficiencies, notablypoor chemical and stress crack resistance, poor resistance tosterilization by gamma radiation, and poor processability.

Blends of polyesters with polycarbonates provide thermoplasticcompositions having improved properties over those based upon either ofthe single resins alone. Further, such blends are often more costeffective than polycarbonate alone. Many applications of engineeringplastics require that these polymers have ignition resistant propertiesalong with other properties such as tensile strength, long-term thermalstability, high heat deflection temperature and chemical resistance.

Despite the use of polycarbonate-polyester blends in electronicapplications, regulatory and product developments have increased thedemand for materials that exhibit specific combination of physicalproperties.

JP2000053860 discloses a composition that contains 100 pts.wt. polyamideresin, 0.1-50 pts.wt. polycarbonate resin, 0-50 pts.wt. polyethyleneterephthalate and 0.1-30 pts.wt. red phosphorus having a conductivity of0.1-1,000 μS/cm. The document indicates that the conductivity of the redphosphorus is the conductivity of the aqueous extract obtained by adding5 g of red phosphorus to 100 ml of deionized water, extraction-treatingthe red phosphorus at 121° C. for 100 hr and diluting the filtrate leftafter the filtration of red phosphorus to 250 ml. The red phosphorusused is desirably one coated with a thermosetting resin, especially, athermoplastic phenolic resin. It is desirable that the compositionadditionally contains 5-140 pts.wt. per 100 pts.wt. polyamide resin.

EP0079177 discloses polyamide compositions with a halogenated organicflame retardant. The compositions are blended with a polymer blendresin, which is at least partially incompatible with and has a lowermelt viscosity than the polyamide, to improve the arc trackingresistance of the polyamide composition. The compositions include from 5to about 30% of a halogen derivative flame retardant and from about 1 to20% of a polymer blend resin. Generally, the composition contains fromabout 30 to 90% by weight polyamide.

Despite documents disclosing such teachings, there remains an unmet needfor formulations that meet specific physical properties. Moreparticularly, there is still an unmet need for compositions that exhibita Glow Wire Ignition Temperature that is at least 775° C. and (ii) aComparative Tracking Index that is at least 250 V. Also, there remainsan unmet need to develop compositions that also impart a flameretardance rating of V0, as per UL 94.

For the foregoing reasons, there is a need to develop improved materialsuseful for making electrical components.

For the foregoing needs, there is a need to develop articles thatexhibit improved properties.

BRIEF DESCRIPTION OF THE INVENTION

The invention relates to a molding composition comprising:

-   -   (a) a polycarbonate component;    -   (b) a polyester component;    -   (c) a polyamide component;    -   (d) a halogenated flame retarding component; and    -   (e) at least one carboxy reactive component;

wherein the polycarbonate component, the polyester component, thepolyamide component, the halogenated flame retarding component, and thecarboxy reactive component are present in sufficient amounts to impart(i) a Glow Wire Ignition Temperature that is at least 775° C. and (ii) aComparative Tracking Index that is at least 250 V to a member selectedfrom the group consisting of the composition, an article molded from thecomposition, an article extruded from the composition, and combinationsthereof.

In one embodiment, the invention relates to a composition of mattercomprising an article derived from a composition comprising:

-   -   (a) a polycarbonate component;    -   (b) a polyester component;    -   (c) a polyamide component;    -   (d) a halogenated flame retarding component;    -   (e) at least one carboxy reactive component;    -   (f) at least one impact modifier

wherein the polycarbonate component, the polyester component, thepolyamide component, the halogenated flame retarding component, and thecarboxy reactive component, and the impact modifier are present insufficient amounts to impart a Glow Wire Ignition Temperature that is atleast 775° C., a flame retardance rating of V0, as per UL 94 and aComparative Tracking Index that is at least 250 V to the article.

In another embodiment, the invention relates to a compositioncomprising:

-   -   (a) from 15 to 40 wt % of a polycarbonate component;    -   (b) from 20 to 40 wt % of a polyester component;    -   (c) from more than 5 to 30 wt % of a polyamide component;    -   (d) from 5 to 15 wt % of a halogenated flame retarding        component;    -   (e) at least 0.1 wt. % of a carboxy reactive component    -   (f) from 0 to 7 wt % of a flame retarding synergist selected        from the group    -   (g) consisting of antimony trioxide, Sb₂O₃, antimony pentoxide        Sb₂O₅, sodium antimonate, and combinations thereof, wherein the        sum of (a), (b), (c), (d), (e) and (f) is 100 wt %.

In another embodiment, the invention relates to a compositioncomprising:

-   -   (a) from 40 to 55 wt % of a polycarbonate component;    -   (a) from 20 to 40 wt % of polyethylene terephthalate;    -   (b) from 2 to 7 wt % of a polyamide component;    -   (c) from 5 to 15 wt % of a halogenated flame retarding        component;    -   (d) from 1 to 3 wt. % of a carboxy reactive component    -   (e) from 3 to 7 wt % of a flame retarding synergist selected        from the group consisting of antimony trioxide, Sb₂O₃, antimony        pentoxide Sb₂O₅, sodium antimonate, and combinations thereof,    -   (f) an impact modifier selected from the group consisting of        acrylic pellets.    -   (g) a mold release agent selected from the group consisting        hydrocarbon mold-release agents, fatty acids, aliphatic        alcohols, polyhydric alcohols, polyglycols, polyglycerols, butyl        stearate, pentaerythritol tetrastearate, and combination        thereof,    -   (h) from 1 to 5 wt % of an additive selected from the group        consisting of talc, hindered phenol stabilizers,        poly(tetrafluoroethylene):styrene-acrylonile, and combinations        thereof,

wherein the sum of (a), (b), (c), (d), (e), (f), (g), (h), and (i) is100 wt %; and

wherein the polycarbonate component, the polyester component, thepolyamide component, and the halogenated flame retarding component, andthe carboxy reactive component are present in sufficient amounts toimpart (i) a Glow Wire Ignition Temperature that is at least 775° C. and(ii) a Comparative Tracking Index that is at least 250 V to a memberselected from the group consisting of the composition, an article moldedfrom the composition, an article extruded from the composition, andcombinations thereof.

And in another embodiment, the invention relates to methods for makingand using the molding composition.

These and other features, aspects, and advantages of the presentinvention will become better understood with reference to the followingdescription and appended claims.

DETAILED DESCRIPTION OF THE INVENTION

The invention is based on the discovery that by using specificcombinations of (a) a polycarbonate component; (b) a polyestercomponent; (c) a polyamide component; (d) a halogenated flame retardingcomponent; and (e) carboxy reactive component, it is possible to obtaina molding composition having a desired combination of physicalproperties. The molding composition is useful in making molded productssuch as electrical components. Advantageously, the composition andarticles made from the composition exhibit excellent performanceproperties.

Other than in the operating examples or where otherwise indicated, allnumbers or expressions referring to quantities of ingredients, reactionconditions, and the like, used in the specification and claims are to beunderstood as modified in all instances by the term “about” variousnumerical ranges are disclosed in this patent application. Because theseranges are continuous, they include every value between the minimum andmaximum values. Unless expressly indicated otherwise, the variousnumerical ranges specified in this application are approximations.

Glow Wire Ignition Temperature (GWIT)—in accordance with IEC 60695-2-13,is expressed as the temperature (in degrees C.), which is 25 C hotterthan the maximum temperature of the tip of the glow-wire which does notcause ignition of the material during three subsequent tests.

Comparative Tracking Index (CTI)—is expressed as that voltage whichcauses tracking after 50 drops of 0.1 percent ammonium chloride solutionhave fallen on the material. The results of testing at the nominal 3 mmthickness are considered representative of the material's performance inany thickness.

The V0 rating is a well-known and accepted flammability performancestandard for plastic materials, as well as UL 94 ratings. This standardis intended to provide an indication of a material's ability toextinguish a flame, once ignited. Several ratings can be applied basedon the rate of burning, time to extinguish, ability to resist dripping,and whether or not drips are burning. Each material tested may receiveseveral ratings based on color and/or thickness. When specifying amaterial for an application, the UL rating should be applicable for thethickness used in the wall section in the plastic part. The UL ratingshould always be reported with the thickness; just reporting the ULrating without mentioning thickness is insufficient. V-0 burning stopswithin 10 seconds on a vertical specimen; no burning drips and no burnto holding clamp allowed. Compositions of this invention can be expectedto achieve a UL94 rating of V0 at a thickness that is suitably lowerthan 1.5 mm and typically at 0.8 mm.

The invention relates to a molding composition comprising:

-   -   (a) a polycarbonate component;    -   (b) a polyester component;    -   (c) a polyamide component;    -   (d) a halogenated flame retarding component; and    -   (e) at least one carboxy reactive component;

wherein the polycarbonate component, the polyester component, thepolyamide component, and the halogenated flame retarding component, andthe carboxy reactive component are present in sufficient amounts toimpart (i) a Glow Wire Ignition Temperature that is at least 775° C. and(ii) a Comparative Tracking Index that is at least 250 V to a memberselected from the group consisting of the composition, an article moldedfrom the composition, an article extruded from the composition, andcombinations thereof.

In one embodiment, the polycarbonate component, the polyester component,the polyamide component, the halogenated flame retarding component andthe carboxy reactive component are present in sufficient amounts toimpart a flame retardance rating of V0, as per UL 94, to a memberselected from the group consisting of the composition, an article moldedfrom the composition, an article extruded from the composition, andcombinations thereof. The composition can impart a Glow Wire IgnitionTemperature that is at least 775° C. to the member at a thicknessselected from the group consisting of 1 mm, 2 mm, and combinationsthereof and (ii) a Comparative Tracking Index that is at least 250 V ata thickness of 3 mm. The composition can also contain the polycarbonatecomponent, the polyester component, the polyamide component, thehalogenated flame retarding component and the carboxy reactive componentare present in sufficient amounts to impart, to the member a flameretardance rating of V0 at a thickness of 0.83 mm, as per UL 94.

The polycarbonate component of the molding composition is describedbelow. As used herein, the terms “polycarbonate” and “polycarbonateresin” mean compositions having repeating structural carbonate units ofthe formula (1):

in which at least 60 percent of the total number of R¹ groups arearomatic organic radicals and the balance thereof are aliphatic,alicyclic, or aromatic radicals. In one embodiment, each R¹ is anaromatic organic radical, for example a radical of the formula (2):

-A¹-Y¹-A²-  (2)

wherein each of A¹ and A² is a monocyclic divalent aryl radical and Y¹is a bridging radical having one or two atoms that separate A¹ from A².In an exemplary embodiment, one atom separates A¹ from A². Illustrativenon-limiting examples of radicals of this type are —O—, —S—, —S(O)—,—S(O₂)—, —C(O)—, methylene, cyclohexyl-methylene,2-[2.2.1]-bicycloheptylidene, ethylidene, isopropylidene,neopentylidene, cyclohexylidene, cyclopentadecylidene,cyclododecylidene, and adamantylidene. The bridging radical y¹ may be ahydrocarbon group or a saturated hydrocarbon group such as methylene,cyclohexylidene, or isopropylidene.

As used herein, the term “aliphatic” refers to a hydrocarbon radicalhaving a valence of at least one including a linear or branched array ofcarbon atoms which is not cyclic; “aromatic” refers to a radical havinga valence of at least one including at least one aromatic group;“cycloaliphatic” refers to a radical having a valence of at least oneincluding an array of carbon atoms which is cyclic but not aromatic;“alkyl” refers to a straight or branched chain monovalent hydrocarbonradical; “alkylene” refers to a straight or branched chain divalenthydrocarbon radical; “alkylidene” refers to a straight or branched chaindivalent hydrocarbon radical, with both valences on a single commoncarbon atom; “alkenyl” refers to a straight or branched chain monovalenthydrocarbon radical having at least two carbons joined by acarbon-carbon double bond; “cycloalkyl” refers to a non-aromaticalicyclic monovalent hydrocarbon radical having at least three carbonatoms, with at least one degree of unsaturation; “cycloalkylene” refersto a non-aromatic alicyclic divalent hydrocarbon radical having at leastthree carbon atoms, with at least one degree of unsaturation; “aryl”refers to a monovalent aromatic benzene ring radical, or to anoptionally substituted benzene ring system radical system fused to atleast one optionally substituted benzene rings; “arylene” refers to abenzene ring diradical or to a benzene ring system diradical fused to atleast one optionally substituted benzene rings; “acyl” refers to amonovalent hydrocarbon radical joined to a carbonyl carbon atom, whereinthe carbonyl carbon further connects to an adjoining group; “alkylaryl”refers to an alkyl group as defined above substituted onto an aryl asdefined above; “arylalkyl” refers to an aryl group as defined abovesubstituted onto an alkyl as defined above; “alkoxy” refers to an alkylgroup as defined above connected through an oxygen radical to anadjoining group; “aryloxy” refers to an aryl group as defined aboveconnected through an oxygen radical to an adjoining group; and “directbond”, where part of a structural variable specification, refers to thedirect joining of the substituents preceding and succeeding the variabletaken as a “direct bond.”

Polycarbonates may be produced by the interfacial reaction of dihydroxycompounds having the formula HO—R¹—OH, which includes dihydroxycompounds of formula (3)

HO-A¹-Y¹-A²-OH  (3)

wherein Y¹, A¹ and A² are as described above. Also included arebisphenol compounds of general formula (4):

wherein R^(a) and R^(b) each represent a halogen atom or a monovalenthydrocarbon group and may be the same or different; p and q are eachindependently integers of 0 to 4; and X^(a) represents one of the groupsof formula (5):

wherein R^(c) and R^(d) each independently represent a hydrogen atom ora monovalent linear or cyclic hydrocarbon group and Re is a divalenthydrocarbon group.

Some illustrative, non-limiting examples of suitable dihydroxy compoundsinclude the following: resorcinol, 4-bromoresorcinol, hydroquinone,4,4′-dihydroxybiphenyl, 1,6-dihydroxynaphthalene,2,6-dihydroxynaphthalene, bis(4-hydroxyphenyl)methane,bis(4-hydroxyphenyl)diphenylmethane,bis(4-hydroxyphenyl)-1-naphthylmethane, 1,2-bis(4-hydroxyphenyl)ethane,1,1-bis(4-hydroxyphenyl)-1-phenylethane,2-(4-hydroxyphenyl)-2-(3-hydroxyphenyl) propane,bis(4-hydroxyphenyl)phenylmethane,2,2-bis(4-hydroxy-3-bromo-phenyl)propane, 1,1-bis(hydroxyphenyl)cyclopentane, 1,1-bis(4-hydroxyphenyl)cyclohexane,1,1-bis(4-hydroxy-3 methyl phenyl)cyclohexane1,1-bis(4-hydroxyphenyl)isobutene,1,1-bis(4-hydroxyphenyl)cyclododecane,6,6′-dihydroxy-3,3,3′,3′-tetramethylspiro(bis)indane (“spirobiindanebisphenol”), 3,3-bis(4-hydroxyphenyl)phthalide,2,6-dihydroxydibenzo-p-dioxin, 2,6-dihydroxythianthrene,2,7-dihydroxyphenoxathin, 2,7-dihydroxy-9,10-dimethylphenazine,3,6-dihydroxydibenzofuran, 3,6-dihydroxydibenzothiophene, and2,7-dihydroxycarbazole, and the like, as well as combinations includingat least one of the foregoing dihydroxy compounds.

Specific examples of the types of bisphenol compounds represented byformula (3) include 1,1-bis(4-hydroxyphenyl) methane,1,1-bis(4-hydroxyphenyl) ethane, 2,2-bis(4-hydroxyphenyl) propane(hereinafter “bisphenol A” or “BPA”), 2,2-bis(4-hydroxyphenyl) butane,2,2-bis(4-hydroxyphenyl) octane, 1,1-bis(4-hydroxyphenyl) propane,1,1-bis(4-hydroxyphenyl) n-butane, 2,2-bis(4-hydroxy-1-methylphenyl)propane, 1,1-bis(4-hydroxy-t-butylphenyl) propane,3,3-bis(4-hydroxyphenyl) phthalimidine,2-phenyl-3,3-bis(4-hydroxyphenyl)phthalimidine (PPPBP), and1,1-bis(4-hydroxy-3-methylphenyl)cyclohexane (DMBPC). Combinationsincluding at least one of the foregoing dihydroxy compounds may also beused.

Branched polycarbonates are also useful, as well as blends of a linearpolycarbonate and a branched polycarbonate. The branched polycarbonatesmay be prepared by adding a branching agent during polymerization. Thesebranching agents include polyfunctional organic compounds containing atleast three functional groups selected from hydroxyl, carboxyl,carboxylic anhydride, haloformyl, and mixtures of the foregoingfunctional groups. Specific examples include trimellitic acid,trimellitic anhydride, trimellitic trichloride, tris-p-hydroxy phenylethane, isatin-bis-phenol, tris-phenol TC(1,3,5-tris((p-hydroxyphenyl)isopropyl)benzene), tris-phenol PA(4(4(1,1-bis(p-hydroxyphenyl)-ethyl) alpha, alpha-dimethylbenzyl)phenol), 4-chloroformyl phthalic anhydride, trimesic acid, andbenzophenone tetracarboxylic acid. The branching agents may be added ata level of 0.05 to 2.0 wt. % of the polycarbonate. All types ofpolycarbonate end groups are contemplated as being useful in thepolycarbonate, provided that such end groups do not significantly affectdesired properties of the thermoplastic compositions.

In a specific embodiment, the polycarbonate is a linear homopolymerderived from bisphenol A, in which each of A¹ and A² is p-phenylene andY¹ is isopropylidene. The polycarbonates may have an intrinsicviscosity, as determined in chloroform at 25° C., of 0.3 to 1.5deciliters per gram (dl/g), specifically 0.45 to 1.0 dl/g. Thepolycarbonates may have a weight average molecular weight (Mw) of 10,000to 100,000, as measured by gel permeation chromatography (GPC) using acrosslinked styrene-divinyl benzene column, at a sample concentration of1 milligram per milliliter, and as calibrated with polycarbonatestandards.

“Polycarbonates” and “polycarbonate resin” as used herein may includecopolymers including carbonate chain units. A specific suitablecopolymer is a polyester-polycarbonate, also known as acopolyester-polycarbonate and polyestercarbonate. Combinations ofpolycarbonates and polyester-polycarbonates may also be used. As usedherein, a “combination” is inclusive of all mixtures, blends, alloys,reaction products, and the like. Polyester-polycarbonates contain, inaddition to recurring carbonate chain units of the formula (1),repeating units of formula (6):

wherein D is a divalent radical derived from a dihydroxy compound, andmay be, for example, a C₂₋₁₀ alkylene radical, a C₆₋₂₀ alicyclicradical, a C₆₋₂₀ aromatic radical or a polyoxyalkylene radical in whichthe alkylene groups contain 2 to 6 carbon atoms, specifically 2,3, or 4carbon atoms; and T divalent radical derived from a dicarboxylic acid,and may be, for example, a C₂₋₁₀ alkylene radical, a C₆₋₂₀ alicyclicradical, a C₆₋₂₀ alkyl aromatic radical, or a C₆₋₂₀ aromatic radical.

In one embodiment, D is a C₂₋₆ alkylene radical. In another embodiment,D is derived from an aromatic dihydroxy compound of formula (7):

wherein each R^(f) is independently a halogen atom, a C₁₋₁₀ hydrocarbongroup, or a C₁₋₁₀ halogen substituted hydrocarbon group, and n is 0 to4. The halogen is usually bromine. Examples of compounds that may berepresented by the formula (7) include resorcinol, substitutedresorcinol compounds such as 5-methyl resorcinol, 5-ethyl resorcinol,5-propyl resorcinol, 5-butyl resorcinol, 5-t-butyl resorcinol, 5-phenylresorcinol, 5-cumyl resorcinol, 2,4,5,6-tetrafluoro resorcinol,2,4,5,6-tetrabromo resorcinol, or the like; catechol; hydroquinone;substituted hydroquinones such as 2-methyl hydroquinone, 2-ethylhydroquinone, 2-propyl hydroquinone, 2-butyl hydroquinone, 2-t-butylhydroquinone, 2-phenyl hydroquinone, 2-cumyl hydroquinone,2,3,5,6-tetramethyl hydroquinone, 2,3,5,6-tetra-t-butyl hydroquinone,2,3,5,6-tetrafluoro hydroquinone, 2,3,5,6-tetrabromo hydroquinone, orthe like; or combinations including at least one of the foregoingcompounds.

Specifically, the polyester unit of a polyester-polycarbonate can bederived from the reaction of a combination of isophthalic andterephthalic diacids (or derivatives thereof) with resorcinol, bisphenolA, or a combination including one or more of these, wherein the molarratio of isophthalate units to terephthalate units is 91:9 to 2:98,specifically 85:15 to 3:97, more specifically 80:20 to 5:95, and stillmore specifically 70:30 to 10:90. The polycarbonate units can be derivedfrom resorcinol and/or bisphenol A, in a molar ratio of resorcinolcarbonate units to bisphenol A carbonate units of 0:100 to 99:1, and themolar ratio of the mixed isophthalate-terephthalate polyester units tothe polycarbonate units in the polyester-polycarbonate can be 1:99 to99:1, specifically 5:95 to 90:10, more specifically 10:90 to 80:20.Where a blend of polyester-polycarbonate with polycarbonate is used, theweight ratio of polycarbonate to polyester-polycarbonate in the blendcan be, respectively, 1:99 to 99:1, specifically 10:90 to 90:10.

The polyester-polycarbonates may have a weight-averaged molecular weight(Mw) of 1,500 to 100,000, specifically 1,700 to 50,000, and morespecifically 2,000 to 40,000. Molecular weight determinations areperformed using gel permeation chromatography (GPC), using a crosslinkedstyrene-divinylbenzene column and calibrated to polycarbonatereferences. Samples are prepared at a concentration of about 1 mg/ml,and are eluted at a flow rate of about 1.0 ml/min.

Suitable polycarbonates can be manufactured by processes such asinterfacial polymerization and melt polymerization. Although thereaction conditions for interfacial polymerization may vary, anexemplary process generally involves dissolving or dispersing a dihydricphenol reactant in aqueous caustic soda or potash, adding the resultingmixture to a suitable water-immiscible solvent medium, and contactingthe reactants with a carbonate precursor in the presence of a suitablecatalyst such as triethylamine or a phase transfer catalyst, undercontrolled pH conditions, e.g., 8 to 10. The most commonly used waterimmiscible solvents include methylene chloride, 1,2-dichloroethane,chlorobenzene, toluene, and the like. Suitable carbonate precursorsinclude, for example, a carbonyl halide such as carbonyl bromide orcarbonyl chloride, or a haloformate such as a bishaloformates of adihydric phenol (e.g., the bischloroformates of bisphenol A,hydroquinone, or the like) or a glycol (e.g., the bishaloformate ofethylene glycol, neopentyl glycol, polyethylene glycol, or the like).Combinations containing at least one of the foregoing types of carbonateprecursors may also be used. A chain stopper (also referred to as acapping agent) may be included during polymerization. The chain-stopperlimits molecular weight growth rate, and so controls molecular weight inthe polycarbonate. A chain-stopper may be at least one of mono-phenoliccompounds, mono-carboxylic acid chlorides, and/or mono-chloroformates.

For example, mono-phenolic compounds suitable as chain stoppers includemonocyclic phenols, such as phenol, C₁-C₂₂ alkyl-substituted phenols,p-cumyl-phenol, p-tertiary-butyl phenol, hydroxy diphenyl; monoethers ofdiphenols, such as p-methoxyphenol. Alkyl-substituted phenols includethose with branched chain alkyl substituents having 8 to 9 carbon atoms.A mono-phenolic UV absorber may be used as capping agent. Such compoundsinclude 4-substituted-2-hydroxybenzophenones and their derivatives, arylsalicylates, monoesters of diphenols such as resorcinol monobenzoate,2-(2-hydroxyaryl)-benzotriazoles and their derivatives,2-(2-hydroxyaryl)-1,3,5-triazines and their derivatives, and the like.Specifically, mono-phenolic chain-stoppers include phenol,p-cumylphenol, and/or resorcinol monobenzoate.

Mono-carboxylic acid chlorides may also be suitable as chain stoppers.These include monocyclic, mono-carboxylic acid chlorides such as benzoylchloride, C₁-C₂₂ alkyl-substituted benzoyl chloride, toluoyl chloride,halogen-substituted benzoyl chloride, bromobenzoyl chloride, cinnamoylchloride, 4-nadimidobenzoyl chloride, and mixtures thereof; polycyclic,mono-carboxylic acid chlorides such as trimellitic anhydride chloride,and naphthoyl chloride; and mixtures of monocyclic and polycyclicmono-carboxylic acid chlorides. Chlorides of aliphatic monocarboxylicacids with up to 22 carbon atoms are suitable. Functionalized chloridesof aliphatic monocarboxylic acids, such as acryloyl chloride andmethacryoyl chloride, are also suitable. Also suitable aremono-chloroformates including monocyclic, mono-chloroformates, such asphenyl chloroformate, alkyl-substituted phenyl chloroformate, p-cumylphenyl chloroformate, toluene chloroformate, and mixtures thereof.

The amount of the polycarbonate component varies with the specificapplication. Generally, the amount of the polycarbonate component varieswith the specific application. Generally, The amount of thepolycarbonate component varies with the specific application. Generally,the amount of the polycarbonate component is present in an amount thatis at least 15 wt. %. In one embodiment, the polycarbonate component ispresent in an amount ranging from 15 to 40 wt %. In another embodiment,the amount of polycarbonate present in the composition ranges from 15 to45 wt. %. In another embodiment, the polycarbonate component is presentin an amount ranging from 15 wt % to 50 wt %. In another embodiment, thepolycarbonate component is present in an amount ranging from 40 wt % to55 wt %.

Suitable polyesters include those including structural units of thefollowing formula:

wherein each R¹ is independently a divalent aliphatic, alicyclic oraromatic hydrocarbon or polyoxyalkylene radical, or mixtures thereof andeach A¹ is independently a divalent aliphatic, alicyclic or aromaticradical, or mixtures thereof. Examples of suitable polyesters containingthe structure of the above formula are poly(alkylene dicarboxylates),liquid crystalline polyesters, and polyester copolymers. It is alsopossible to use a branched polyester in which a branching agent, forexample, a glycol having three or more hydroxyl groups or atrifunctional or multifunctional carboxylic acid has been incorporated.Furthermore, it is sometimes desirable to have various concentrations ofacid and hydroxyl end groups on the polyester, depending on the ultimateend-use of the composition.

The R¹ radical may be, for example, a C₂₋₁₀ alkylene radical, a C₆₋₁₂alicyclic radical, a C₆₋₂₀ aromatic radical or a polyoxyalkylene radicalin which the alkylene groups contain about 2-6 and most often 2 or 4carbon atoms. The A¹ radical in the above formula is most often p- orm-phenylene, a cycloaliphatic or a mixture thereof. This class ofpolyester includes the poly(alkylene terephthalates). Such polyestersare known in the art as illustrated by the following patents, which areincorporated herein by reference. U.S. Pat. Nos. 2,465,319; 2,720,502;2,727,881; 2,822,348; 3,047,539; 3,671,487; 3,953,394 and 4,128,526.

Examples of aromatic dicarboxylic acids represented by thedicarboxylated residue A¹ are isophthalic or terephthalic acid,1,2-di(p-carboxyphenyl)ethane, 4,4′-dicarboxydiphenyl ether, 4,4′bisbenzoic acid and mixtures thereof. Acids containing fused rings canalso be present, such as in 1,4-1,5- or 2,6-naphthalenedicarboxylicacids. The preferred dicarboxylic acids are terephthalic acid,isophthalic acid, naphthalene dicarboxylic acid, cyclohexanedicarboxylic acid or mixtures thereof. Particularly suitable polyestersare poly(ethylene terephthalate) (“PET”), and poly(1,4-butyleneterephthalate), (“PBT”), poly(butylene naphthanoate), (“PBN”),poly(cyclohexanedimethylene terephthalate) (“PCT”),cyclohexanedimethanol modified poly(ethylene terephthalate also known aspolycyclohexylenedimethylene ethylene terephthalate) (“PETG” and“PCTG”), and (polypropylene terephthalate) (“PPT”), and mixturesthereof.

Also contemplated herein are the above polyesters with minor amounts,e.g., from 0.5 to about 25 percent by weight, of units derived fromaliphatic acid and/or aliphatic polyols to form copolyesters. Thealiphatic polyols include glycols, such as polytetramethylene glycol orpoly(ethylene glycol) or poly(butylene glycol). Such polyesters can bemade by known processes, e.g., those taught by the teachings in U.S.Pat. Nos. 2,465,319 and 3,047,539.

The amount of the polyester component can vary, depending on theapplication. In one embodiment, the polyester component is present in anamount that is at least 20 wt. %. In another embodiment, the polyestercomponent is present in an amount ranging from 20 to 40 wt %.

The polyamide component generally includes at least one polyamide, suchthat when it is used in accordance to the invention, the resultingcomposition imparts useful properties.

Suitable polyamide resins are a generic family of resins known asNylons, characterized by the presence of an amide group (—C(O)NH—).Nylon-6 and Nylon-6,6 are the generally preferred polyamides and areavailable from a variety of commercial sources. Other polyamides,however, such as Nylon-4,6, Nylon-12, Nylon-6,10, Nylon-6,9, Nylon-6/6Tand Nylon-6,6/6T with triamine contents below 0.5 weight percent, aswell as others, such as the amorphous Nylons may be useful forparticular poly(arylene ether)-polyamide applications. Mixtures ofvarious polyamides, as well as various polyamide copolymers, are alsouseful. A highly preferred polyamide is Nylon-6, 6.

The polyamides can be obtained by a number of well known processes suchas those described in U.S. Pat. Nos. 2,071,250; 2,071,251; 2,130,523;2,130,948; 2,241,322; 2,312,966; and 2,512,606. Nylon-6, for example, isa polymerization product of caprolactam. Nylon-6,6 is a condensationproduct of adipic acid and 1,6-diaminohexane. Likewise, Nylon-4,6 is acondensation product of adipic acid and 1,4-diaminobutane. Besidesadipic acid, other useful diacids for the preparation of Nylons includeazelaic acid, sebacic acid, dodecane diacid, as well as terephthalic andisophthalic acids, and the like. Other useful diamines include m-xylyenediamine, di-(4-aminophenyl)methane, di-(4-aminocyclohexyl)methane,2,2-di-(4-aminophenyl)propane, 2,2-di-(4-aminocyclohexyl)propane, amongothers. Copolymers of caprolactam with diacids and diamines are alsouseful.

Specific examples of polyamides include those selected frompolycaproamide, polyhexamethylene adipamide, polyhexathylene sebacamide,polyundecamethylene adipamide, polyundecanamide, polydodecanamidecopolymerized polyamides of the foregoing, and combinations thereof. Asuitable selection of polaymides can be selected from the groupconsisting of Nylon-6 and Nylon-6,6 Nylon-4,6, Nylon-12, Nylon-6,10,Nylon-6,9, Nylon-6/6T, Nylon-6,6/6T, polycaproamide, polyhexamethyleneadipamide, polyhexathylene sebacamide, polyundecamethylene adipamide,polyundecanamide, polydodecanamide copolymerized polyamides of theforegoing, and combinations thereof.

The amount of the polyamide component is generally more than 5 wt %. Inone embodiment, the amount of the polyamide component is at least 10 wt%. In one embodiment, the amount of the polyamide component ranges from5 to 30 wt %, or 10 to 30 wt %. In another embodiment, the amount of thepolyamide component ranges from 20 to 25 wt. %.

The halogenated fire retarding component can include any halogenatedfire retarding agent, which when used in accordance with the invention,produces a molding composition that exhibits useful properties. Examplesof suitable halogenated fire retarding agents include and are notlimited to ethane-1,2-bis[pentabromophenyl, brominated polystyrene,poly(pentabromobenzylacrylate), 1,2-bis-(tetrabromophthalimido)ethane,phenol-capped carbonate pentamers of tetrabromobisphenol-A-carbonateoligomers (TBBPA), 2,4,6-tribromophenol cappedtetrabromobisphenolA-carbonate oligomers, brominated polycarbonates,tetrabromo bisphenol a diglycidyl ether & brominated. The halogenatedfire retarding components are made by known methods and are commerciallyavailable from various vendors.

The amount of the halogenated fire retarding component can vary,depending on application. Generally, the flame retarding component ispresent in an amount that is at least 5 wt %. In one embodiment, theamount of the halogenated fire retarding component ranges from 5 to 15wt %, or from 5 to 30 wt %, or more. In another embodiment, the amountof the halogenated fire retarding component ranges from 6 to 8 wt %. Thehalogen content can vary, depending on composition and needs. In oneembodiment, for instance, the bromine content is can be at least about 5wt %, based on the weight of the halogenated fire retardingcompositions.

The halogenated fire retarding component can be used in conjunction withflame retarding synergists. Suitable synergists can be selected from thegroup of antimony trioxide, Sb₂O₃, antimony pentoxide Sb₂O₅, sodiumantimonate, and combinations thereof. Such synergists can be used inamounts that are at least 2 or 3 wt %. Specific ranges can be from 2 to7 wt %, or more, or 3 to 7 wt %, or more.

The carboxy reactive component is generally added to improve thehomogeneity of blends and is a polyfunctional carboxy reactive materialthat can be either polymeric or non-polymeric. Accordingly, the carboxyreactive component can be selected from the group consisting ofpolymeric polyfunctional carboxy reactive materials, non-polymericcarboxy reactive materials, and combinations thereof. Examples ofcarboxy reactive groups include and are not limited to epoxides,carbodiimides, orthoesters, oxazolines, oxiranes, aziridines,anhydrides, reactive silicone containing materials of the foregoing, andcombinations thereof.

The carboxy reactive material can also include other functionalitiesthat are either reactive or non-reactive under the described processingconditions. Non-limiting examples of reactive moieties include reactivesilicone containing materials, for example epoxy modified siliconemonomers and polymeric materials. If desired, a catalyst or co-catalystsystem can be used to accelerate the reaction between the polyfunctionalcarboxy-reactive material and other components of the composition. Theterm “poly” means at least two functional groups that can react with acarboxy group.

Particularly useful polyfunctional carboxy reactive materials includematerials with more than one reactive epoxy group. The polyfunctionalepoxy compound may contain aromatic and/or aliphatic residues. Typicalexamples used in the art include3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexanecarboxylate, epoxy phenolNOVOLAC™ ™ resins, epoxy cresol NOVOLAC™ resins, epoxidized vegetable(soybean, linseed) oils, styrene-acrylic copolymers containing pendantglycidyl groups and glycidyl methacrylate containing oligomers, polymersand copolymers.

Preferred materials with multiple epoxy groups are styrene-acryliccopolymers and oligomers containing glycidyl groups incorporated as sidechains. Several useful examples are described in the InternationalPatent Application WO 03/066704 A1 assigned to Johnson Polymer, LLC,incorporated herewith. These materials are based on oligomers withstyrene and acrylate building blocks that have desirable glycidyl groupsincorporated as side chains. A high number of epoxy groups per oligomerchain is desired, at least about 10, preferably greater than about 15,and more preferably greater than about 20. These polymeric materialsgenerally have a molecular weight greater than about 3000, preferablygreater than about 4000, and more preferably greater than about 6000.These are commercially available from Johnson Polymer, LLC under theJoncryl™. trade name, preferably Joncryl™ ADR 4368 material. It is alsocommonly referred to as CESA ADR 4368. Other preferred materials withmultiple epoxy groups are other acrylic or polyolefin copolymers andoligomers containing glycidyl groups incorporated as side chains.

Epoxy functionalized materials are available from Dow Chemical Companyunder the trade name DER-332, from Resolution Performance Products underthe trade name EPON Resin 1001F, 1004F, 1005F, 1007F, and 1009F; fromShell Oil Corporation under the trade names Epon 826, 828, and 871; fromCiba-Giegy Corporation under the trade names CY-182 and CY-183; and fromDOW under the trade name ERL-4221 and ERL-4299.

In one embodiment, the carboxy reactive component can have impactmodifying properties. An example of such a carboxy reactive material isa co- or ter-polymer including units of ethylene and glycidylmethacrylate (GMA), sold by Arkema. Typical composition of such glycidylester impact modifier is about 67 wt % ethylene, 25 wt % methylmethacrylate and 8 wt % glycidyl methacrylate impact modifier, availablefrom Atofina under the brand name LOTADER 8900). Another example of acarboxy reactive component that has impact modifying properties is aterpolymer made of ethylene, butyl acrylate and glycidyl methacrylate(e.g., the ELVALOY PT or PTW series from Dupont).

The amount of the carboxy reactive component is generally at least 0.01wt. %. In one embodiment, the amount of the polyfunctional carboxyreactive component ranges from 0.01 to 10 wt %, depending on thespecific compound. In one embodiment, the amount of the carboxy reactivecomponent ranges from 0.1 to 0.3 wt %.

The composition can further comprise at least one impact modifier. Suchimpact modifiers are not carboxy reactive. The impact modifiersgenerally is a material, which when used in accordance with theinvention, improves the impact properties of the composition. Usefulimpact modifiers are substantially amorphous copolymer resins, includingbut not limited to acrylic rubbers, ASA rubbers, diene rubbers,organosiloxane rubbers, EPDM rubbers, SBS or SEBS rubbers, ABS rubbers,MBS rubbers and glycidyl ester impact modifiers. The acrylic rubber ispreferably core-shell polymers built up from a rubber-like core on whichone or more shells have been grafted. Typical core material consistssubstantially of an acrylate rubber. Preferable the core is an acrylaterubber of derived from a C4 to C12 acrylate. Typically, one or moreshells are grafted on the core. Usually these shells are built up forthe greater part from a vinyl aromatic compound and/or a vinyl cyanideand/or an alkyl(meth)acrylate and/or (meth)acrylic acid. Preferable theshell is derived from an alkyl(meth)acrylate, more preferable amethyl(meth)acrylate. The core and/or the shell(s) often comprisemulti-functional compounds that may act as a cross-linking agent and/oras a grafting agent. These polymers are usually prepared in severalstages. The preparation of core-shell polymers and their use as impactmodifiers are described in U.S. Pat. Nos. 3,864,428 and 4,264,487.Especially preferred grafted polymers are the core-shell polymersavailable from Rohm & Haas under the trade name PARALOID®, including,for example, PARALOID® EXL3691 and PARALOID® EXL3330, EXL3300 andEXL2300. Core shell acrylic rubbers can be of various particle sizes.The preferred range is from 300-800 nm, however larger particles, ormixtures of small and large particles, may also be used. In someinstances, especially where good appearance is required acrylic rubberwith a particle size of 350-450 nm may be preferred. In otherapplications where higher impact is desired acrylic rubber particlesizes of 450-550 nm or 650-750 nm may be employed. Acrylic impactmodifiers contribute to heat stability and UV resistance as well asimpact strength of polymer compositions. Other preferred rubbers usefulherein as impact modifiers include graft and/or core shell structureshaving a rubbery component with a Tg (glass transition temperature)below 0° C., preferably between about −40° to about −80° C., whichcomprise poly-alkylacrylates or polyolefins grafted withpoly(methyl)methacrylate or styrene-acrylonitrile copolymer. Preferablythe rubber content is at least about 10% by weight, most preferably, atleast about 50%.

Typical other rubbers for use as impact modifiers herein are thebutadiene core-shell polymers of the type available from Rohm & Haasunder the trade name PARALOID® EXL2600. Most preferably, the impactmodifier will comprise a two stage polymer having a butadiene basedrubbery core, and a second stage polymerized from methylmethacrylatealone or in combination with styrene. Impact modifiers of the type alsoinclude those that comprise acrylonitrile and styrene grafted ontocross-linked butadiene polymer, which are disclosed in U.S. Pat. No.4,292,233 herein incorporated by reference.

Other suitable impact modifiers may be mixtures comprising core shellimpact modifiers made via emulsion polymerization using alkyl acrylate,styrene and butadiene. These include, for example,methylmethacrylate-butadiene-styrene (MBS) andmethylmethacrylate-butylacrylate core shell rubbers.

Among the other suitable impact modifiers are the so-called blockcopolymers and rubbery impact modifiers, for example, A-B-A triblockcopolymers and A-B diblock copolymers. The A-B and A-B-A type blockcopolymer rubber additives which may be used as impact modifiers includethermoplastic rubbers comprised of one or two alkenyl aromatic blockswhich are typically styrene blocks and a rubber block, e.g., a butadieneblock which may be partially hydrogenated. Mixtures of these triblockcopolymers and diblock copolymers are especially useful.

Suitable A-B and A-B-A type block copolymers are disclosed in, forexample, U.S. Pat. Nos. 3,078,254, 3,402,159, 3,297,793, 3,265,765, and3,594,452 and U.K. Patent 1,264,741. Examples of typical species of A-Band A-B-A block copolymers include polystyrene-polybutadiene (SB),polystyrene-poly(ethylene-propylene), polystyrene-polyisoprene,poly(α-methylstyrene)-polybutadiene,polystyrene-polybutadiene-polystyrene (SBS),polystyrene-poly(ethylene-propylene)-polystyrene, polystyrene-polyisoprene-polystyrene andpoly(α-methylstyrene)-polybutadiene-poly(α-methylstyrene), as well asthe selectively hydrogenated versions thereof, and the like. Mixturescomprising at least one of the aforementioned block copolymers are alsouseful. Such A-B and A-B-A block copolymers are available commerciallyfrom a number of sources, including Phillips Petroleum under thetrademark SOLPRENE, Shell Chemical Co., under the trademark KRATON,Dexco under the trade name VECTOR, and Kuraray under the trademarkSEPTON.

The impact modifier can also include a vinyl aromatic-vinyl cyanidecopolymer. Suitable vinyl cyanide compounds include acrylonitrile andsubstituted vinyl cyanides such a methacrylonitrile. Preferably theimpact modifier comprises styrene-acrylonitrile copolymer (hereinafterSAN). The preferred SAN composition comprises at least 10, preferably 25to 28, percent by weight acrylonitrile (AN) with the remainder styrene,para-methyl styrene, or alpha methyl styrene. Another example of SANsuseful herein include those modified by grafting SAN to a rubberysubstrate such as, for example, 1,4-polybutadiene, to produce a rubbergraft polymeric impact modifier. High rubber content (greater than 50%by weight) resin of this type (HRG-ABS) may be especially useful forimpact modification of polyester resins and their polycarbonate blends.

Another class of preferred impact modifiers, referred to as high rubbergraft ABS modifiers, comprise greater than or equal to about 90% byweight SAN grafted onto polybutadiene, the remainder being free SAN. ABScan have butadiene contents between 12% and 85% by weight and styrene toacrylonitrile ratios between 90:10 and 60:40. Preferred compositionsinclude: about 8% acrylonitrile, 43% butadiene and 49% styrene, andabout 7% acrylonitrile, 50% butadiene and 43% styrene, by weight. Thesematerials are commercially available under the trade names BLENDEX 336and BLENDEX 415 respectively (Crompton Co.).

Improved impact strength is obtained by melt compounding polybutyleneterephthalate with ethylene homo- and copolymers functionalized witheither acid or ester moieties as taught in U.S. Pat. Nos. 3,405,198;3,769,260; 4,327,764; and 4,364,280. Polyblends of polybutyleneterephthalate with a styrene-alpha-olefin-styrene triblock are taught inU.S. Pat. No. 4,119,607. U.S. Pat. No. 4,172,859 teaches impactmodification of polybutylene terephthalate with random ethylene-acrylatecopolymers and EPDM rubbers grafted with a monomeric ester or acidfunctionality.

Preferred impact modifiers include core-shell impact modifiers, such asthose having a core of poly(butyl acrylate) and a shell of poly(methylmethacrylate).

When an impact modifier is used, the amount of the impact modifier isgenerally at least 2 wt. %. A combination of impact modifiers can alsobe used. In one embodiment, the total amount of impact modifiers usedranges from 2 wt % to 10 wt % and more preferably from 2 wt % to 7 wt.

The composition can also contain other additives. In one embodiment, themolding composition can further include mold-release agents. Examples ofthe mold-release agents include, but are not limited to natural andsynthetic paraffins, polyethylene waxes, fluorocarbons, and otherhydrocarbon mold-release agents; stearic acid, hydroxystearic acid, andother higher fatty acids, hydroxyfatty acids, and other fatty acidmold-release agents; stearic acid amide, ethylenebisstearamide, andother fatty acid amides, alkylenebisfatty acid amides, and other fattyacid amide mold-release agents; stearyl alcohol, cetyl alcohol, andother aliphatic alcohols, polyhydric alcohols, polyglycols,polyglycerols and other alcoholic mold release agents; butyl stearate,pentaerythritol tetrastearate, and other lower alcohol esters of fattyacid, polyhydric alcohol esters of fatty acid, polyglycol esters offatty acid, and other fatty acid ester mold release agents; silicone oiland other silicone mold release agents, and mixtures of any of theaforementioned. The mold release agent can be used in conjunction withother additives, e.g., TEFLON styrene acrylonitrile

The amount of the mold release agent can be in the molding compositionis generally at least 0.1 wt. %. In one embodiment, the amount of themold release agent ranges from 0.1 to 2 wt. %. In another embodiment,the amount of the mold release agent ranges from 0.5 to 1 wt. %.

A molding composition of the invention may further contain a heatstabilizer. Suitable heat stabilizers include, but are not limited to,hindered phenol stabilizers, organic thioether stabilizers, organicphosphite stabilizers, hindered amine stabilizers, epoxy stabilizers andmixtures thereof. The heat-resistant stabilizer may be added in the formof a solid or liquid.

The amount of the heat stabilizer that can be in the molding compositionis generally at least 0.01 wt. %. In one embodiment, the amount of theheat stabilizer ranges from 0.01 to 0.5 wt. %. In another embodiment,the amount of the heat stabilizer ranges from 0.05 to 1 wt. %. Inanother embodiment, the amount of the heat stabilizer ranges from 0.05to 3 wt. %.

Other additives include and are not limited to mono zinc phosphate,antioxidants, Sb₂O₃—PBT masterbatch materials, low density polyethylene,potassium diphenylsulphone sulfonate, Ultratalc, pentaerythritoltetrastearate, and Teflon powder. The amount of such additionaladditives can vary. Generally, the amount is at least 0.01 wt. %. In oneembodiment, the amount of the heat stabilizer ranges from 0.01 to 0.5wt. %. In another embodiment, the amount of the heat stabilizer rangesfrom 0.05 to 1 wt. %. In another embodiment, the amount of the heatstabilizer ranges from 0.05 to 3 wt. %.

A molding composition of the invention is generally made by combiningsuitable amounts of the a polycarbonate component; the polyestercomponent, the polyamide component; the halogenated flame retardingcomponent; and the carboxy reactive component, in an extruder (or afunctionally equivalent compounding device) under suitable conditions.The polycarbonate component; the polyester component, the polyamidecomponent; the halogenated flame retarding component; the impactmodifier and the carboxy reactive component (and any additionalcomponents) may be compounded simultaneously, separately, or incombinations containing two or three of the components. The extrusionprocess can include one or more passes through an extruder.

An article is generally made typically by injection molding using thefollowing procedure. Injection molding is a process wherein an amount ofpolymer several times that necessary to produce an article is heated ina heating chamber to a viscous liquid and then injected under pressureinto a mold cavity. The polymer remains in the mold cavity under highpressure until it is cooled and is then removed. The term “injectionmolding” also encompasses the relatively new advance of reactioninjection molding, wherein a two part semi-liquid resin blend is made toflow through a nozzle and into a mold cavity where it polymerizes as aresult of a chemical reaction. Injection molding and injection moldingapparatii are discussed in further detail in U.S. Pat. Nos. 3,915,608 toHujick; 3,302,243 to Ludwig; and 3,224,043 to Lameris. Injection moldingis the fastest of the thermoplastic processes, and thus is generallyused for large volume applications such as automotive and consumergoods. The cycle times range between 20 and 60 seconds. Injectionmolding also produces highly repeatable near-net shaped parts. Theability to mold around inserts, holes and core material is anotheradvantage. Finally, injection molding generally offer the best surfacefinish of any process. The skilled artisan will know whether injectionmolding is the best particular processing method to produce a givenarticle according to the present invention. In one embodiment, pelletsof the composition are dried in an oven over a suitable period, e.g., 12hrs. at 120° C., molded in injection molding machine with a suitablemelt temperature profile, e.g., 100-240-250-260-260° C., where thetemperature of the mold is kept suitably for processing, e.g., at 60° C.

Accordingly, the invention provides articles with many usefulproperties. In one embodiment, the invention relates to an articlecomprising:

-   -   (a) a polycarbonate component;    -   (b) a polyester component;    -   (c) a polyamide component;    -   (d) a halogenated flame retarding component;    -   (e) at least one carboxy reactive component;    -   (f) at least one impact modifier

wherein the polycarbonate component, the polyester component, thepolyamide component, the halogenated flame retarding component, and thecarboxy reactive component, and the impact modifier are present insufficient amounts to impart a Glow Wire Ignition Temperature that is atleast 775° C., a flame retardance rating of V0, as per UL 94 and aComparative Tracking Index that is at least 250 V to the article.

In another embodiment, the invention relates to a molding compositioncontaining:

-   -   (a) from 15 to 40 wt % of a polycarbonate component;    -   (b) from 20 to 40 wt % of a polyester component;    -   (c) from more than 5 to 30 wt % of a polyamide component;    -   (d) from 5 to 15 wt % of a halogenated flame retarding        component;    -   (e) at least 0.1 wt. % of a carboxy reactive component    -   (f) from 0 to 7 wt % of a flame retarding synergist selected        from the group consisting of antimony trioxide, Sb₂O₃, antimony        pentoxide Sb₂O₅, sodium antimonate, and combinations thereof;        wherein the sum of (a), (b), (c), (d), (e) and (f) is 100 wt %.

It will be appreciated, however, that embodiments of our invention caninclude other compositions. For instance, the composition can include:

-   -   (a) from 40 to 55 wt % of a polycarbonate component;    -   (b) from 20 to 40 wt % of polyethylene terephthalate;    -   (c) from 2 to 7 wt % of a polyamide component;    -   (d) from 5 to 15 wt % of a halogenated flame retarding        component;    -   (e) from 1 to 3 wt. % of a carboxy reactive component    -   (f) from 3 to 7 wt % of a flame retarding synergist selected        from the group consisting of antimony trioxide, Sb₂O₃, antimony        pentoxide Sb₂O₅, sodium antimonate, and combinations thereof,    -   (g) an impact modifier selected from the group consisting of        acrylic pellets    -   (h) a mold release agent selected from the group consisting        hydrocarbon mold-release agents, fatty acids, aliphatic        alcohols, polyhydric alcohols, polyglycols, polyglycerols, butyl        stearate, pentaerythritol tetrastearate, and combination        thereof;    -   (i) from 1 to 5 wt % of an additive selected from the group        consisting of talc, hindered phenol stabilizers,        poly(tetrafluoroethylene):styrene-acrylonile, and combinations        thereof; such that the sum of (a), (b), (c), (d), (e), (f), (g),        (h), and (i) is 100 wt %. The halogenated flame retarding agent        can be halogenated flame retarding agent is brominated        polystyrene and wherein the sum of (a), (b), (c), (d), (e), (f),        (g), (h), and (i) is 100 wt %; and wherein the polycarbonate        component, the polyester component, the polyamide component, and        the halogenated flame retarding component, and the carboxy        reactive component are present in sufficient amounts to        impart (i) a Glow Wire Ignition Temperature that is at least        775° C. and (ii) a Comparative Tracking Index that is at least        250 V to a member selected from the group consisting of the        composition, an article molded from the composition, an article        extruded from the composition, and combinations thereof. Such a        composition can also include components in the amounts indicated        their respective descriptions.

Advantageously, our composition does not require materials that arefound in conventional compositions. For instance, our composition can beeffective without the presence of red phosphorous. In one embodiment,our composition contains less than 5 wt % of red phosphorous. In anotherembodiment, our composition contains less than 3 or 2, or 1 wt % of redphosphorous. In another embodiment, our composition does not contain anyred phosphorous.

Our compositions can be used to make compositions of matter comprisingarticles. Examples of suitable articles include and are not limited torelay housing controls, timer housing structures, connectors, controlsand switches. In one embodiment, for instance, a suitable article mayinclude an electric connector which includes a connector shell and aconductor rack, the conductor rack including a-shaped rack body having atop wall, a bottom wall, and a side wall connected between a rear end ofthe top wall and a rear end of the bottom wall at one end, the bottomwall having a plurality of wire holes at a front end thereof, and aplurality of conductors respectively inserted through the wire holes onthe bottom wall and extended out of the rack body. It will beappreciated that such articles can be derived from compositionsdescribed herein.

The invention includes embodiments in which compositions used to makesuch above-mentioned articles contain polycarbonate in an amount rangingfrom 15 to 45 wt %, the polyester component is present in an amountranging from 20 to 40 wt %, the polyamide component is present in anamount ranging in an amount ranging from 10 to 30 wt %, the halogenatedflame retarding component is present in an amount ranging from 5 to 15wt. %, and the carboxy reactive is present in an amount ranging from 1to 10 wt % and the impact modifier is present in an amount ranging from1 to 10%; wherein the sum of the wt % of the polycarbonate, thepolyester component, the polyamide component, the halogenated flameretarding component, the carboxy reactive component, and the impactmodifier is 100 wt %. In another embodiment, the polycarbonate componentis present in an amount ranging from 15 to 45 wt %, the polyestercomponent is present in an amount ranging from 20 to 40 wt %, thepolyamide component is present in an amount ranging in an amount rangingfrom 10 to 30 wt %, the halogenated flame retarding component is presentin an amount ranging from 5 to 15 wt. %, the carboxy reactive componentis present in an amount ranging from 1 to 10 wt %; wherein the sum ofthe polycarbonate, the polyester component, the polyamide component, thehalogenated flame retarding component, the carboxy reactive component,and the impact modifier is 100 wt %.

The physical properties of the compositions and the articles made, e.g.(articles molded or extruded from the compositions) from thecompositions generally exhibit highly useful combination of GWIT, CTIand flame retarding properties. Generally, the polycarbonate component,the polyester component, the polyamide component, the halogenated flameretarding component, and the carboxy reactive component are present insufficient amounts to impart (i) a GWIT that is at least 775° C. and(ii) a CTI that is at least 250 V to the composition or to an articlemolded or extruded from the composition. Particularly suitablecompositions (and articles molded or extruded from the compositions)also exhibit a flame retardance rating of V0, as per UL 94. Ourcompositions can impart GWIT, CTI, and V0 properties at variousthicknesses. For instance, the composition can impart a Glow WireIgnition Temperature that is at least 775° C. at a thickness selectedfrom the group consisting of 1 mm, 2 mm, and combinations thereof and(ii) a Comparative Tracking Index that is at least 250 V at a thicknessof 3 mm and (iii) a flame retardance rating of V0 at a thickness of 0.83mm, as per UL 94 to a member selected from the group consisting of thecomposition, an article molded from the composition, an article extrudedfrom the composition, and combinations thereof.

The invention is further described in the following illustrativeexamples in which all parts and percentages are by weight unlessotherwise indicated.

EXAMPLES Examples 1-19 and Comparative Examples 1-4 Standards/Procedures

Glow Wire Ignition Temperature (GWIT)—in accordance with IEC 695-2-1/3,was expressed as the temperature (in degrees C.), which is 25 C hotterthan the maximum temperature of the tip of the glow-wire which does notcause ignition of the material during three sequential tests. Since thetarget requirement of GWIT for the inventive compositions was 775 deg C.at 2 mm thickness, a pass/fail criterion was employed. If the GWIT valueexceeded 775 deg C., the respective composition was deemed to havepassed the test. If GWIT was less than 775 deg C., it was deemed to havefailed the test.

Comparative Tracking Index (CTI)—was expressed as that voltage whichcauses tracking after 50 drops of 0.1 percent ammonium chloride solutionhave fallen on the material. The results of testing the nominal 3 mmthickness were considered representative of the material's performancein any thickness. Since the target CTI requirement was 250 Volts, if acomposition passed the 250 volts requirement by the method described asabove, it was considered to have passed the CTI test. If it is notpassing the test, it is deemed to have failed. Wherever possible, thetest has been conducted at 400 volts and 600 volts as well. Similarpass/fail criterion was employed for those voltages as well.

Tensile Property Testing

Tensile properties were tested according to ISO 527 on 150×10×4×mm(length×wide×thickness) injection molded bars at 23° C. with a crossheadspeed of 5 mm/min. Izod unnotched impact was measured at 23° C. with apendulum of 5.5 Joule on 80×10×4 mm (length×wide×thickness) impact barsaccording to ISO 180 method. Flexural properties or three point bendingwere measured at 23° C. on 80×10×4 mm (length×wide×thickness) impactbars with a crosshead speed of 2 mm/min according to ISO 178.

In other cases, injection molded parts were tested by ASTM. Notched Izodtesting was done on 3×½×⅛ inch bars using ASTM method D256. Tensileelongation at break was tested on 7×⅛ in. injection molded bars at roomtemperature with a crosshead speed of 2 in./min for glass filled samplesand 0.2 in/min for un-filled samples by using ASTM D648. Flexuralproperties were measured using ASTM 790 or ISO 178 method.

Flame retardancy tests were performed following the procedure ofUnderwriter's Laboratory Bulletin 94 entitled “Tests for Flammability ofPlastic Materials, UL94.” According to this procedure, materials may beclassified as HB, V0, V1, V2, VA and/or VB on the basis of the testresults obtained for five samples. To achieve a rating of V0, in asample placed so that its long axis is 180 degrees to the flame, theaverage period of flaming and/or smoldering after removing the ignitingflame does not exceed five seconds and none of the vertically placedsamples produces drips of burning particles that ignite absorbentcotton. Five bar flame out time (FOT) is the sum of the flame out timefor five bars, each lit twice for a maximum flame out time of 50seconds. To achieve a rating of V1, in a sample placed so that its longaxis is 180 degrees to the flame, the average period of flaming and/orsmoldering after removing the igniting flame does not exceed twenty-fiveseconds and none of the vertically placed samples produces drips ofburning particles that ignite absorbent cotton. Five bar flame out timeis the sum of the flame out time for five bars, each lit twice for amaximum flame out time of 250 seconds. Compositions of this inventionare expected to achieve a UL94 rating of V1 and/or V0 at a thickness ofpreferably lower than 1.5 mm and typically at 0.8 mm.

Preparation of Molding Compositions: General Method

The materials used for the preparation of blends are given in theTable 1. The blends were obtained by mixing known amounts ofpolycarbonates, polyamide 6, polyethylene terephthalate, different FRadditives and impact modifiers and other additives by weights as givenin Table 2-5. The blending was carried out on a 37 mm Toshiba TEM-37BSco-rotating Twin Screw Extruder with a screw speed of about 300 rotationper minute. The final temperature employed during compounding was about250 to 260° C. to form a melt. The melt was then extruded in the form ofstrand that was cooled through a water bath prior to pelletization. Thepellets were dried for about −10 hours at about 120° C. in a forcedair-circulating oven prior to molding. The samples were injection moldedin 100 ton Injection Molding machine as per ASTM test protocolrequirements. The temperature profile used for injection molding was100-240-250-260-260° C.

TABLE 1 Raw Materials Item Description CAS# Source Matrix Polymers PCPolycarbonate high flow grade 111211-39-3 GE Plastics PC Polycarbonateof low flow grade PET PET (IV 0.64) 25038-59-9 Foshan PA 6 Nylon 625038-54-4 DOMO PBT Polybutyleneterephthalate 30965-26-5 GE PlasticsCARBOXY REACTIVE COMPONENTS CESA Styrene-acrylate-epoxy oligomer /Johnson Polymer LOTADER E-GMA-MA 51541-08-3 PCT Atofina IMPACT MODIFIERSIM 2 Methylmethacrylate Butadiene Styrene — ROHM & HASS copolymer IMACRYLIC POLYMER IMPACT 25852-37-3 ROHM & HASS MODIFIER, PELLETS Flameretardants Br-FR-1 Decabromodiphenylethane 84852-53-9 Chemtura Br-EpoxyBROMINATED EPOXY, NF 300 VLG 68928-70-1 Alteco chem Br-FR-32,4,6-tribromophenol capped 71342-77-3 Great LakeTetraBromoBisPhenolA-carbonate oligomer Br-PC Brominated Polycarbonate156042-31-8 GEP Br-PS Brominated Polystyrene 88497-56-7 Great Lake/Albemarle Br-Acrylic Poly(pentabromobenzylacrylate) 59447-57-3 EUROBROMOBr-FR-2 1,2-bis(tetrabromophthalimido)ethane 32588-76-4 Albemarle Otheradditives MZP Mono zinc phosphate 13598-37-3 Siam Union AO Antioxidant1010 6683-19-8 CIBA Sb₂O₃ MB Sb₂O₃ PBT masterbatch 1309-64-4 GEP BOZLDPE Low density polyethylene 25087-34-7 NOVA CHEMICALS KSS Potassiumdiphenylsulphone sulfonate 63316-43-8 Metropolitan Eximchem UltratalcUltratalc 16389-88-1 Cronell Bros PETS Pentaerythritol tetrastearate115-83-3 Cognis Teflon Teflon powder 9002-84-0 Dupont

TABLE 2 Item Unit C. Ex. 1 C. Ex. 2 Ex. 1 Matrix Resin PA 6 wt. % 0.0020.00 20.00 PC* wt. % 28.00 18.00 28.00 PET wt. % 57.02 47.02 37.12PA:(PC + PET) none 0.00 1:3.25 1:3.25 PC:(PA + PET) none 1:2.04 1:3.721:2.04 Flame retardants Br-FR-1 wt. % 5.00 5.00 5.00 Br-Epoxy wt. % 2.002.00 2.00 Bromine content wt. % 5.07 5.07 5.07 CESA wt. % 0.10 0.10 0.10Other Additives MZP wt. % 0.02 0.02 0.02 AO wt. % 0.06 0.06 0.06 Sb₂O₃MB wt. % 5.00 5.00 5.00 LDPE wt. % 1.50 1.50 1.50 KSS wt. % 0.20 0.200.20 Ultratalc wt. % 0.50 0.50 0.50 PETS wt. % 0.50 0.50 0.50 Teflon wt.% 0.10 0.10 0.10 Performance characteristics GWIT 1 mm (775 C.)Pass/fail Pass Fail Pass GWIT 2 mm (775 C.) Pass/fail Pass Fail Pass CTI250 V Pass/fail fail pass pass MVR at 265 C./2.16 cc/10 min 27.55 24.720.28 Kg/240 s Flexural Modulus Mpa 2420 2420 2390 Flexural Strength-YMpa 96.2 97.8 96.3 Flexural Strength-B Mpa 94.4 95.9 94.5 IZOD-NotchedkJ/m2 34.782 30.43 34.266 Tensile Moduls Mpa 2894 3054 3218 TensileStrength MPa 40.1 63.3 61.6 Tensile Elongation wt. % 12 4.1 4.8 Heatdistortion temperature deg C. 119 127 125 (0.45 mPa) *The ratio of highto low molecular weight polycarbonate employed is about 2.

From the results of Example 1 given in Table 2, satisfactory CTI andGWIT performances were obtained when a suitable combination ofpolycarbonate, polyethylene terephthalate and polyamide-6,6 wasemployed. Both CTI and GWIT requirements were passed when the ratio ofPC (PA+PET) was 1:2.04 and PA:(PC+PET) ratio was 1:3.25.

When polyamide was absent (C. Ex. 1), the CTI requirement was not met.When the ratio of PC to (PA+PET) was 1:3.72 (C. Ex. 2), the compositiondid not pass the GWIT test (775 deg C., 2 mm).

TABLE 3 Effect of flame retardants Item Unit Ex. 2 Ex. 3 Ex. 4 Ex. 5 Ex.6 C. Ex. 3 Matrix Polymer PA 6 wt. % 20.00 20.00 20.00 20.00 20.00 20.00PC wt. % 28.00 28.00 28.00 28.00 28.00 20.00 PET wt. % 36.92 36.35 36.3536.35 35.18 30.79 PA: (PC + PET) none 1:3.25 1:3.25 1:3.25 1:3.25 1:3.151:3.0  PC: (PA + PET) none 1:2.04 1:2.01 1:2.01 1:2.01 1:1.97 1:2.54Flame Retardants Br-PC wt. % 0.00 0.00 0.00 0.00 0.00 21.13 Br-PS wt. %0.00 7.57 0.00 0.00 0.00 0.00 Br-Acylic wt. % 0.00 0.00 7.57 0.00 0.000.00 Br-FR 2 wt. % 0.00 0.00 0.00 7.57 0.00 0.00 Br-FR 3 wt. % 0.00 0.000.00 0.00 8.74 0.00 Br-FR-1 wt. % 5.00 0.00 0.00 0.00 0.00 0.00 Br-Epoxywt. % 2.00 0.00 0.00 0.00 0.00 0.00 Bromine content wt. % 5.06 5.07 5.075.07 5.07 5.07 in formulation CESA wt. % 0.10 0.10 0.10 0.10 0.10 0.10Other Additives MZP wt. % 0.02 0.02 0.02 0.02 0.02 0.02 AO wt. % 0.060.06 0.06 0.06 0.06 0.06 Sb₂O₃ MB wt. % 5.00 5.00 5.00 5.00 5.00 5.00LDPE wt. % 1.50 1.50 1.50 1.50 1.50 1.50 KSS wt. % 0.20 0.20 0.20 0.200.20 0.20 Ultratalc wt. % 0.50 0.50 0.50 0.50 0.50 0.50 PETS wt. % 0.500.50 0.50 0.50 0.50 0.50 Teflon wt. % 0.20 0.20 0.20 0.20 0.20 0.20Performance Characteristics GWIT 1 mm 775 C. Pass/Fail Pass Pass PassPass Pass Pass GWIT 2 mm 775 C. Pass/Fail Pass Pass Pass Pass Pass PassCTI 250 V Pass/Fail Pass Pass Pass Pass Pass Fail IZOD-Notched kJ/m228.6 17.7 22.6 20.5 26.5 33.3 Flexural Mpa 2210 2220 2250 2470 2400 2330Modulus Flexural Mpa 88.4 91.8 92.2 94.8 95.6 95.7 Strength-B HeatDistortion C. 105 103 105 104 107 112 Temperature- HDT (1.82 Mpa)Tensile Modulus Mpa 2692 2848 2882 3042 2786 2660 Tensile Strength Mpa39.3 49.8 54.6 60.7 59.3 29.7 Tensile wt. % 7.9 2.7 3.3 3.8 4.0 22Elongation MVR at 265 C./ cc/10 min 16.77 16.66 18.65 21.48 22.12 19.642.16 Kg/240 s

As seen in Table 3, acceptable results of GWIT and CTI were obtainedwith a wide variety of brominated flame-retardants. When a brominatedoligocarbonate of 50 wt. % bromine content (Example 6) is used, thecomposition passed both CTI and GWIT requirements. However, acomposition with brominated polycarbonate at the indicated amount didnot pass the CTI test (See C. Ex. 3).

TABLE 4 Description Unit Ex. 9 Ex. 10 Ex. 11 Ex. 12 Ex. 13 Ex. 14 Ex. 15Ex. 16 Ex. 17 Nylon 6 wt. % 20.00 10 15 20 10 15 20 10 20 PCP1300 wt. %10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 100 Grade PCP wt.% 18.00 22.00 18.00 18.00 20.00 18.00 15.00 18.00 13.00 PET wt. % 36.9240.92 39.92 34.92 38.92 35.92 33.92 36.92 31.92 PC/(PET + PA) — 1:2.031:1.59 1:1.96 1:1.96 1:1.63 1:1.82 1:2.16 1:1.68 1:2.26 PA/(PET + PC) —1:3.25 1:7.29 1:4.53 1:3.15 1:6.89 1:4.26 1:2.95 1:6.49 1:2.75 LOTADERwt. % 0.00 2 2 2 6 6 6 10 10 AX8900 CESA wt. % 0.10 0.10 0.10 0.10 0.100.10 0.10 0.10 0.10 Flame retardants Br-FR-1 wt. % 5.00 5.00 5.00 5.005.00 5.00 5.00 5.00 5.00 Br-epoxy wt. % 2.00 2.00 2.00 2.00 2.00 2.002.00 2.00 2.00 Final Bromine wt. % 5.07 5.07 5.07 5.07 5.07 5.07 5.075.07 5.07 content in formula Other Additives MZP wt. % 0.02 0.02 0.020.02 0.02 0.02 0.02 0.02 0.02 Antioxidant 1010 wt. % 0.06 0.06 0.06 0.060.06 0.06 0.06 0.06 0.06 Sb₂O₃, MB wt. % 5.00 5.00 5.00 5.00 5.00 5.005.00 5.00 5.00 LLDPE wt. % 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50KSS wt. % 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 Ultratalc 609 wt.% 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 0.50 PETS wt. % 0.50 0.50 0.500.50 0.50 0.50 0.50 0.50 0.50 PTFE powder wt. % 0.20 0.20 0.20 0.20 0.200.20 0.20 0.20 0.20 Performance characteristics CTI 250 V Pass/fail PassPass Pass Pass Pass Pass Pass Pass Pass GWIT, 1 mm at 775 C. Pass/failPass Pass Pass Pass Pass Pass Pass Pass Pass GWIT, 2 mm at 775 C.Pass/fail Pass Pass Pass Pass Pass Pass Pass Pass Pass

As seen from Table 4, the presence of impact modifiers did not affectthe GWIT/CTI balance of the inventive compositions. When the impactmodifier was greater than about 6%, the mechanical properties,particularly tensile modulus became lower by greater than about 25% ofthe original tensile modulus value and hence considered unsuitable insome connector applications. Generally, a good balance of GWIT and CTIrequirement is met when the ratio of PA:(PET+PC) is in the range of1:1.0 to 1:15 and the ratio of PC (PET+PA) is in the range of 1:0.7 to1:3.3

TABLE 5 Ingredients Unit Ex. 18 Ex. 19 Matrix polymer PA 6 wt. % 15 15PC wt. % 10.00 10.00 PC wt. % 18.00 18.00 PET wt. % 39.32 34.32 PET/PCratio — 1.40 1.23 PA:(PET + PC) — 1:4.49 1:4.15 LOTADER wt. % 2 2 CESAwt. % 0.10 0.10 Impact modifier IM wt. % 0.00 5.00 Flame retardantsBr-FR-1 wt. % 5.60 5.60 Br-Epoxy wt. % 2.00 2.00 Other Additives MZP wt.% 0.02 0.02 AO wt. % 0.06 0.06 Sb₂O₃ MB wt. % 5.00 5.00 LDPE wt. % 1.501.50 KSS wt. % 0.20 0.20 Ultratalc wt. % 0.50 0.50 PETS wt. % 0.50 0.50Teflon wt. % 0.20 0.20 Performance characteristics GWIT 1 mm, 775 C.pass/fail pass pass GWIT 2 mm, 775 C. pass/fail pass pass CTI 250 Vpass/fail pass pass V-0 @0.83 mm pass/fail pass pass IZOD-N J/N 31.752.4

As seen in Table 5, the formulations of the invention exhibitedexcellent flame retardant ratings (UL-94). When an acrylic impactmodifier was present along with LOTADER (E/GMA/MA terpolymer), thenotched Izod impact property was improved.

Comparative Example 4

The procedure of Example 10 was followed except that the amount ofpolyamide amount was 5 wt %. The results obtained indicated that thecomposition did not impart an acceptable GWIT rating.

Example 20

The procedure of Example 1 was repeated, except that the followingformulation was used, as shown in Table 6:

TABLE 6 Description Unit Ex. 20 Nylon 6 wt. % 5 LOTADER AX8900 wt. % 2PET wt. % 21.2 PC/(PET + PA) — 1.9 PA/(PFT + PC) — 0.07 CESA wt. % 0.1Br-FR-1 wt. % 8.5 Final Bromine content in formula wt. % 5.7 MZP wt. %Antioxidant 1010 wt. % 0.1 Sb₂O₃, MB wt. % 6.7 LLDPE wt. % 0.5 KSS wt. %/ Ultratalc 609 wt. % 0.5 PETS wt. % 0.2 TSAN wt. % 0.2

Results

The results of the tests for this formulation indicated that thecomposition passed the following tests, as shown in Table 7:

TABLE 7 CTI 250 V Pass/fail Pass GWIT, 1 mm at 775 C. Pass/fail PassGWIT, 2 mm at 775 C. Pass/fail Pass

Although the present invention has been described in detail withreference to certain preferred versions thereof, other variations arepossible. Therefore, the spirit and scope of the appended claims shouldnot be limited to the description of the versions contained therein.

1. A molding composition comprising: (a) a polycarbonate component; (b)a polyester component; (c) a polyamide component; (d) a halogenatedflame retarding component; and (e) at least one carboxy reactivecomponent; wherein the polycarbonate component, the polyester component,the polyamide component, and the halogenated flame retarding component,and the carboxy reactive component are present in sufficient amounts toimpart (i) a Glow Wire Ignition Temperature that is at least 775° C. and(ii) a Comparative Tracking Index that is at least 250 V to a memberselected from the group consisting of the composition, an article moldedfrom the composition, an article extruded from the composition, andcombinations thereof.
 2. The composition of claim 1, wherein thepolycarbonate component, the polyester component, the polyamidecomponent, the halogenated flame retarding component and the carboxyreactive component are present in sufficient amounts to impart a flameretardance rating of V0, as per UL 94, to a member selected from thegroup consisting of the composition, an article molded from thecomposition, an article extruded from the composition, and combinationsthereof.
 3. The composition of claim 1, wherein the polycarbonatecomponent is present in an amount ranging from 15 to 50 wt %.
 4. Thecomposition of claim 1, wherein the polyester component is selected fromthe group consisting of polyethylene terephthalate, andpoly(1,4-butylene terephthalate, poly(butylene naphthanoate),poly(cyclohexanedimethylene terephthalate, polycyclohexylenedimethyleneethylene terephthalate, polypropylene terephthalate, and combinationsthereof.
 5. The composition of claim 1, wherein the polyester componentis present in an amount ranging from 20 to 40 wt %.
 6. The compositionof claim 1, wherein the polyamide component is selected from the groupconsisting of Nylon-6 and Nylon-6,6 Nylon-4,6, Nylon-12, Nylon-6,10,Nylon-6,9, Nylon-6/6T, Nylon-6,6/6T, polycaproamide, polyhexamethyleneadipamide, polyhexathylene sebacamide, polyundecamethylene adipamide,polyundecanamide, polydodecanamide copolymerized polyamides of theforegoing, and combinations thereof.
 7. The composition of claim 1,wherein the polyamide component is present in an amount ranging frommore than 5 to 30 wt %.
 8. The composition of claim 1, wherein thehalogenated flame retarding component is selected from the groupconsisting of ethane-1,2-bis[pentabromophenyl, brominated polystyrene,poly(pentabromobenzylacrylate), 1,2-bis-(tetrabromophthalimido)ethane,phenol-capped carbonate pentamers of TetraBromoBis PhenolA-carbonateoligomers, 2,4,6-tribromophenol capped TetraBromoBis PhenolA-carbonateoligomers, brominated polycarbonates, tetrabromo bisphenol a diglycidylether, and combinations thereof.
 9. The composition of claim 1, whereinthe halogenated fire retarding component is present in an amount rangingfrom 5 to 15 wt %.
 10. The composition of claim 1, wherein thehalogenated fire retarding component further comprises flame retardingsynergists selected from the group of antimony trioxide, Sb₂O₃, antimonypentoxide Sb₂O₅, sodium antimonite, and combinations thereof in anamount ranging from 2 to 7 wt %.
 11. The composition of claim 1, whereinthe composition further comprises at least one impact modifier.
 12. Thecomposition of claim 1, wherein the carboxy reactive component isselected from the group consisting of polymeric polyfunctional carboxyreactive materials, non-polymeric carboxy reactive materials, andcombinations thereof.
 13. The composition of claim 1, wherein thecarboxy reactive component is selected from the group consisting ofepoxides, carbodiimides, orthoesters, oxazolines, oxiranes, aziridines,anhydrides, reactive silicone containing materials of the foregoing, andcombinations thereof.
 14. The composition of claim 13, wherein thecarboxy reactive component is a co- or ter-polymer including units ofethylene and glycidyl methacrylate.
 15. The composition of claim 13,wherein the carboxy reactive component is present in an amount that isat least 0.01 wt. %.
 16. A composition of matter comprising an articlederived from a composition comprising: (a) a polycarbonate component;(b) a polyester component; (c) a polyamide component; (d) a halogenatedflame retarding component; (e) at least one carboxy reactive component;(f) at least one impact modifier wherein the polycarbonate component,the polyester component, the polyamide component, the halogenated flameretarding component, and the carboxy reactive component, and the impactmodifier are present in sufficient amounts to impart a Glow WireIgnition Temperature that is at least 775° C., a flame retardance ratingof V0, as per UL 94 and a Comparative Tracking Index that is at least250 V to the article.
 17. The composition of matter of claim 16, whereinthe article is selected from the group consisting of relay housingcontrols, timer housing structures, connectors, controls, switches, andcombinations thereof.
 18. The composition of matter of claim 16, whereinthe polycarbonate component is present in an amount ranging from 15 to55 wt %, the polyester component is present in an amount ranging from 20to 40 wt %, the polyamide component is present in an amount ranging inan amount ranging from 10 to 30 wt %, the halogenated flame retardingcomponent is present in an amount ranging from 5 to 15 wt. %, thecarboxy reactive component is present in an amount ranging from 1 to 10wt % and the impact modifier is present in an amount ranging from 1 to10%; wherein the sum of the wt % of the polycarbonate, the polyestercomponent, the polyamide component, the halogenated flame retardingcomponent, the carboxy reactive component, and the impact modifier is100 wt %.
 19. The composition of matter of claim 17, wherein thepolycarbonate component is present in an amount ranging from 15 to 45 wt%, the polyester component is present in an amount ranging from 20 to 40wt %, the polyamide component is present in an amount ranging in anamount ranging from 10 to 30 wt %, the halogenated flame retardingcomponent is present in an amount ranging from 5 to 15 wt. %, thecarboxy reactive component is present in an amount ranging from 1 to 10wt %; wherein the sum of the polycarbonate, the polyester component, thepolyamide component, the halogenated flame retarding component, thecarboxy reactive component, and the impact modifier is 100 wt %.
 20. Acomposition comprising: (a) from 15 to 40 wt % of a polycarbonatecomponent; (b) from 20 to 40 wt % of a polyester component; (c) frommore than 5 to 30 wt % of a polyamide component; (d) from 5 to 15 wt %of a halogenated flame retarding component; (e) at least 0.1 wt. % of acarboxy reactive component (f) from 0 to 7 wt % of a flame retardingsynergist selected from the group consisting of antimony trioxide,Sb₂O₃, antimony pentoxide Sb₂O₅, sodium antimonate, and combinationsthereof, wherein the sum of (a), (b), (c), (d), (e) and (f) is 100 wt %.21. A composition comprising: (a) from 40 to 55 wt % of a polycarbonatecomponent; (b) from 20 to 40 wt % of polyethylene terephthalate; (c)from 2 to 7 wt % of a polyamide component; (d) from 5 to 15 wt % of ahalogenated flame retarding component; (e) from 1 to 3 wt. % of acarboxy reactive component (f) from 3 to 7 wt % of a flame retardingsynergist selected from the group consisting of antimony trioxide,Sb₂O₃, antimony pentoxide Sb₂O₅, sodium antimonate, and combinationsthereof, (g) an impact modifier selected from the group consisting ofacrylic pellets. (h) a mold release agent selected from the groupconsisting hydrocarbon mold-release agents, fatty acids, aliphaticalcohols, polyhydric alcohols, polyglycols, polyglycerols, butylstearate, pentaerythritol tetrastearate, and combination thereof; (i)from 1 to 5 wt % of an additive selected from the group consisting oftalc, hindered phenol stabilizers,poly(tetrafluoroethylene):styrene-acrylonile, and combinations thereof;wherein the sum of (a), (b), (c), (d), (e), (f), (g), (h), and (i) is100 wt %; and wherein the polycarbonate component, the polyestercomponent, the polyamide component, and the halogenated flame retardingcomponent, and the carboxy reactive component are present in sufficientamounts to impart (i) a Glow Wire Ignition Temperature that is at least775° C. and (ii) a Comparative Tracking Index that is at least 250 V toa member selected from the group consisting of the composition, anarticle molded from the composition, an article extruded from thecomposition, and combinations thereof.
 22. The composition of claim 21,wherein the halogenated flame retarding agent is brominated polystyrene.23. The composition of claim 1, wherein the composition imparts a GlowWire Ignition Temperature that is at least 775° C. to the member at athickness selected from the group consisting of 1 mm, 2 mm, andcombinations thereof and (ii) a Comparative Tracking Index that is atleast 250 V at a thickness of 3 mm.
 24. The composition of claim 2,wherein the wherein the polycarbonate component, the polyestercomponent, the polyamide component, the halogenated flame retardingcomponent and the carboxy reactive component are present in sufficientamounts to impart, to the member a flame retardance rating of V0 at athickness of 0.83 mm, as per UL
 94. 25. The composition of matter ofclaim 16, wherein the composition impartsto the member a Glow WireIgnition Temperature that is at least 775° C. at a thickness selectedfrom the group consisting of 1 mm, 2 mm, and combinations thereof and(ii) a Comparative Tracking Index that is at least 250 V at a thicknessof 3 mm to the member and (iii) a flame retardance rating of V0 at athickness of 0.83 mm, as per UL
 94. 26. The composition of matter ofclaim 20, wherein the composition imparts to the member a Glow WireIgnition Temperature that is at least 775° C. at a thickness selectedfrom the group consisting of 1 mm, 2 mm, and combinations thereof and(ii) a Comparative Tracking Index that is at least 250 V at a thicknessof 3 mm to the member and (iii) a flame retardance rating of V0 at athickness of 0.83 mm, as per UL
 94. 27. The composition of matter ofclaim 21, wherein the composition imparts to the member a Glow WireIgnition Temperature that is at least 775° C. at a thickness selectedfrom the group consisting of 1 mm, 2 mm, and combinations thereof and(ii) a Comparative Tracking Index that is at least 250 V at a thicknessof 3 mm and (iii) a flame retardance rating of V0 at a thickness of 0.83mm, as per UL 94.